New Operation 004o-1/A1

Sulzer
Diesel General
ZA40S Explanations on the Use of the Operating Manual and Cross Section
"----
Contents

The Operating Manual called Operation for short, contains mainly descriptions and indications on the servicing of the
engine in operation, the required operating media (oil, water, air, fuel) as well as explanations of the function of specific
components and system.
The instructions on maintenance and overhauls are found in a separate book, the Maintenance Manual.

Structure and utilization

The individual groups with their illustration part are extensively distributed according to design groups.
In order to have group descriptions universally usable i.e. a module structure possible, the numbering has been arranged
in accordance with two points ofview.
1. By one permanent group number plus a subdivision number:
e.g.: 0040-1

In this way cross-indexes (see group .... - . ) are neutral within the description.
2. After the oblique stroke with a variable designation:
e.g.: IA1

A certain design execution and the attached number of an alternative is assigned to the letter.
Simultaneously such groups are clearly marked by a short variant designation arranged opposite the title.

The numbering for the pages takes place in the middle of the foot of the page, whereby the last page marks the end of the
group description and page number respectively, by a conclusion mark (e).
Remarks refer to the complete group (see group .... - .) within the texts, and not to individual pages.
Every page is provided with a footnote with the year of issue or the last modification (month + year) as well as with
additional remarks.

Where to find what

When looking for group descriptions consult first of all the table of contents 0020-1.
In the cross section illustration, importantcomponents have been marked with the group numberwhere they can quickly
be found with their description. The sections further provide a general view of the design of the engine, which, depending
on specific executions, may differ slightly.
Cross section, see page 2.

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1 1996
0040-1/A1 Operation New
Sulzer
Diesel
ZA40S
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6500-1

8100-1

2705-1
11 11 1 11111 r ~/!W"~
2750-1

2701-1
2716-1
5501-1 ___ CJc 2722-1
2728-1
J
6701-1

5801-1
4401-1 - ( '1' L..J
b1I::f(l~, 1\1 ".,r ~ -lIllL. -:---r--------:Tl1r'- , --- 2105-1

3401-1

::~:~~IIII~III 111~- A1---- 6601-1

4211-1 1 -'- . 1 1 1 1 11 \ 1 1\ H\ \ 1 ru I / / I I I
3301-1

1001-1

1603-1

3101-1

1201-1
1008-1

96.7274

1996 2 • L-Mot.

I
 New Operation OOSQ-1/F1
Sulzar
Diesel General
ZA40S Short Description in Key Words
'-
ZA40S . Four-stroke Diesel engine, built in-line and vee-form, cylinder bore 0 40 cm, stroke
56 cm.
Engine housing (frame) .... Monoblock, carrying all other components.
Crank shaft main bearing .. Split bearing shells, mounted in the engine housing by bearing covers.
Cylinder liner . Supported in the engine housing, water cooled. Bore cooled in the upper part and
provided with longitudinal bores for separate cylinder lubrication, if applied.
Cylinder head . Upper end closure of the cylinder, fastened to the engine housing by hydraulically
tightened studs. Fitted in are inlet/exhaust valves, fuel injection valve, starting valve,
relief valve and indicator valve.
Valve drive . . . . . . . . . . . . . . . From camshaft via push rods and rocker arms.
Crankshaft . One piece construction, fitted with counterweights, gear wheels for camshaft drive
and built-on pumps in certain cases.
Connecting rod . Separated in connecting rod shaft with spherical upper end and crankpin bearing
split, split bearing shell, hydraulically pre-tensioned and fitted compression shirn
depending on cylinder output.
Rotating pisto n . Bore cooled with lubricating oil, fitted with a rotating mechanism, consisting of
several parts, piston crown of steel, piston skirt cast iron.
Camshaft drive . Via intermediate gear wheel from crankshaft.
Camshaft . The camshaft carries the inlet and exhaust valve cams as well as the fuel injection cam
for each cylinder. The cams are shrunk-on hydraulically. There are fitted also driving
wheel for governor drive and overspeed safety cut-out, flywheel disc or vibration
damper depending on the number of cylinders and application.
Starting air control . With solenoid valve via shut-off valve for starting air and starting air distributor to
starting valve in the cylinder head.
Speed governor . Driven off camshaft drive wheel, mechanic/hydraulic or electronic.
Overspeed cut-out device .. The mechanical overspeed safety cut-out device shuts the engine down in case of
overspeed by shifting the regulating linkage to zero fuel.
The electro-pneumatic safety cut-out device acts on the pisto n of regulating racks of
all fuel injection pumps and in turn interrupts the fuel delivery until a lower engine
speed is reached (however the engine is not shut down).
Fuel injection . Fuel injection pump (Bosch-type) driven off camshaft (fuel cam), direct injection via
high pressure pipe, fuel stud and nozzle holder to injection nozzle.
Regulating linkage . Mechanical connection speed governor or actuator to fuel injection pumps.
Exhaust gas turbocharger .. Driven by exhaust gases, compresses the charge air.
Charge air cooler . Cools the charge air heated by compression. In normal cases through two-stage
charge air cooler by means of high temperature circuit and low temperature circuit
with treated fresh water.
Engine-driven pumps . Oil pump, fuel delivery pump (only for engines operated on Diesel oil) and cooling
water pumps can be driven directly off the engine.
The pump~ for the auxiliary systems are normally driven by electric motors.
Instrument panel . The most important system pressures and engine speed can be read off this panel
during operation.

F 1 • 1996
 New Operation 006o-1/A1
Sulzer
Diesel General
ZA40S Working PrincipIe of the Four-Stroke Diese! Engine
<..
During one working cycle the crankshaft turns twice.

First stroke:

Through the opened inlet valve compressed air is pressed by the exhaust gas turbocharger via charge air cooler into the
cylinder. The piston moves downwards. During this period the crankshaft goes through a half turno The first stroke is
also designated suction stroke.

Second stroke:
With closed valves the air in the cylinder is compressed by the upwards moving piston. Before the top dead centre
(T.D.C.) is reached by the piston, fuel is injected into the combustion space. Here too the crankshaft goes through a
half turno The second stroke is designated compression stroke.

Third stroke:

The injected, atomized fuel ignites in the hot compressed air of the combustion space. Combustion and with it
expansion begins and presses the piston downwards. The crankshaft goes through a further half turno The third stroke
is designated working stroke or expansion stroke.

Fourth stroke:
The exhaust valve opens and the combustion gases are pressed out of the cylinder by the upwards moving piston. These
exhaust gases drive the turbine and with it the blower of the turbocharger. The crankshaft goes through a further half
turno The fourth stroke is designated exhaust stroke or scavenging stroke.

First stroke Second stroke Third stroke Fourth stroke

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95.8523
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1 • 1996

I
 New Operation 0080-1/A1
Sulzer
Diesel General
ZA40S Numbering of Cylinders, Bearings and Engine Sides Interpretation
'-----'

Turbocharger (Optional) Crankshaft Main Bearing Bearing Number

FUEL PUMP SIDE

o
z o
w z
w
(.!J 1 11
Z w
s w
a:
a:o LL

1 2 3 4 5 6

EXHAUST SI DE

Thrust Bearing Camshaft Driving Wheel Cylinder Number Turbocharger

FUEL PUMP SIDE

Exhaust valve Inlet valve

o
z o
w z
w
(.!J
z w
s w
a:
a:o LL

Exhaust valve Inlet valve

EXHAUST SIDE

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DIRECTION OF ROTATION VIEWED FROM DRIVING END

Camshaft

Crankshaft

'----" CLOCKWISE ROTATION ANTI-CLOCKWISE ROTATION

L-Mot. 1 • 1996